WO2018158928A1 - 設備保全支援システム及び設備保全支援方法 - Google Patents
設備保全支援システム及び設備保全支援方法 Download PDFInfo
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- WO2018158928A1 WO2018158928A1 PCT/JP2017/008410 JP2017008410W WO2018158928A1 WO 2018158928 A1 WO2018158928 A1 WO 2018158928A1 JP 2017008410 W JP2017008410 W JP 2017008410W WO 2018158928 A1 WO2018158928 A1 WO 2018158928A1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B23/00—Testing or monitoring of control systems or parts thereof
- G05B23/02—Electric testing or monitoring
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
Definitions
- the present invention relates to a facility maintenance support system and a facility maintenance support method for supporting the work of a worker (maintenance staff) who maintains a production facility installed at a production site.
- the system described in Japanese Patent Laid-Open No. 2001-159916 is connected to a data management device that manages equipment inspection information of various facilities, and the data management device via a communication interface device. And a portable input / output device that performs transmission and reception.
- the data management device includes a management device-side storage unit that stores facility inspection information including a circulation order when various facilities are inspected.
- the portable input / output device includes an input / output device side storage unit and a tour target display unit.
- the input / output device side storage means stores facility inspection information from the data management device that is taken in via the communication interface device.
- the traveling object display means sequentially displays the traveling object on the screen for each predetermined operation based on the traveling order included in the equipment inspection information stored in the input / output device storage means.
- the portable input / output device can be used to efficiently and reliably check the equipment without depending on the skill level of the worker.
- a maintenance staff or a patrol in the maintenance office using PHS (Personal Handy-phone System) or an extension telephone While confirming the work status of the maintenance staff of each individual, the person in charge of maintenance (contact personnel) is determined and dispatched to the maintenance request destination.
- PHS Personal Handy-phone System
- the present invention has been made in consideration of such problems.
- Information can be shared among production sites, maintenance staff, and management offices using communication means.
- An equipment maintenance support system and equipment maintenance support method that can grasp at a glance the progress of maintenance work in response to requests from production sites and the efficiency of maintenance staff who maintain production equipment The purpose is to provide.
- An equipment maintenance support system is an equipment maintenance support system that supports maintenance of one or more production facilities installed at a production site, and includes at least one server and one or more servers.
- a terminal and one or more management monitors are arranged as necessary for each maintenance staff office, production staff office, warehouse, and production line, and a maintenance request from the terminal arranged in the production line is made.
- means for displaying at least the management monitor and the terminal a layout screen showing an arrangement position of one or more production facilities installed at the production site, and from the production line You may have a means to reflect a request
- various requests can be input while looking directly at the layout screen using a display connected to a terminal installed at each production line or a management monitor connected to a server.
- the input request can be reflected on the layout screen.
- the request content for the production facility can be easily confirmed by a person other than the requested staff or the like looking at the layout screen.
- the maintenance request includes at least primary determination information indicating a mechanical trouble or an electric trouble.
- the maintenance request is displayed in a state in which a layout screen showing an arrangement position of one or more production facilities installed on the production site is displayed on the terminal arranged on the production line. It is preferably carried out by manual input of production staff. As a result, the maintenance request is reflected on the layout screen, so the production staff can easily check whether the maintenance request has been made correctly for the equipment that requires the maintenance request by making a maintenance request while looking at the layout screen. can do.
- the maintenance request manually input by the production staff includes at least information on parts necessary for maintenance and a storage location of the parts.
- the maintenance request includes information on the parts required for maintenance and the storage location of the parts, the maintenance staff can easily obtain the parts required for maintenance and perform maintenance work. The time until the start can be shortened, and the efficiency of maintenance work can be improved.
- the maintenance request manually input by the production staff includes information on troubles that have occurred in the past.
- the maintenance request includes information related to troubles that have occurred in the past, so maintenance personnel can efficiently carry out maintenance work while checking the information, and shorten the maintenance work time. It is possible to improve the efficiency of maintenance work.
- the maintenance request manually input by the production staff includes information on a maintenance staff comment on the trouble that has occurred in the past.
- the maintenance request includes information related to comments from maintenance staff regarding troubles that have occurred in the past.Even for equipment that the maintenance person is in charge of for the first time, referring to the comments enables efficient maintenance work. This makes it possible to improve the efficiency of maintenance work.
- At least the terminal arranged on the production line is instructed by the maintenance staff when the secondary judgment made after the maintenance work by the maintenance staff is different from the primary judgment. There may be means for requesting support based on the above.
- the maintenance staff can efficiently advance the maintenance work together with the support staff, and the efficiency of the maintenance work can be improved.
- the support request is made by the maintenance staff in a state in which a layout screen showing an arrangement position of one or more production facilities installed on the production site is displayed on the terminal arranged on the production line. It is preferable that it is implemented by manual input by a person.
- the support request is reflected in the layout screen, so the maintenance staff can easily check whether the support request has been made correctly for the equipment that requires the support request by making a support request while looking at the layout screen. Can be confirmed.
- At least the terminal arranged on the production line includes means for requesting support when an elapsed time of maintenance work by the maintenance staff exceeds a preset time. You may have.
- the time may be forgotten and the opportunity to request support may be missed. Therefore, when the elapsed time of maintenance work by the maintenance staff exceeds a preset time, a support request can be made, thereby reducing the burden on the maintenance staff.
- the maintenance staff can efficiently perform the maintenance work together with the support staff, and the efficiency of the maintenance work can be improved.
- At least the terminal arranged on the production line outputs an alarm indicating an abnormality of the maintenance work when the maintenance work elapsed time by the maintenance person exceeds a preset time. May be.
- the terminal arranged on the production line may have means for displaying a maintenance plan for production facilities on the production line based on an instruction from the maintenance staff.
- the system has an equipment monitoring system that monitors an operation status of the production equipment arranged in the production line, and the equipment monitoring system detects the abnormality of the production equipment when the abnormality is detected.
- a maintenance request is made to the terminal installed at the maintenance staff office, and the terminal installed at the maintenance staff office further receives means for receiving the maintenance request from the equipment monitoring system, and the received maintenance request. May be displayed on at least the management monitor installed in the maintenance staff office.
- the equipment monitoring system When the equipment monitoring system detects an abnormality in the production equipment, it issues a maintenance request to the terminal installed in the maintenance staff office, so it can issue a maintenance request more quickly than a maintenance request manually input by the production staff. .
- the maintenance staff since the maintenance request by the equipment monitoring system is displayed on the management monitor installed in the maintenance staff office, the maintenance staff can recognize the maintenance request by the equipment monitoring system at an early stage and maintenance work is required. Maintenance work for various facilities can be carried out at an early stage.
- At least one server, one or more terminals, and one or more management monitors include a maintenance staff office, a production staff office, a warehouse, An equipment maintenance support method that is arranged for each production line as needed and is used in an equipment maintenance support system that supports the maintenance of one or more production equipment installed at a production site.
- information can be shared using the communication means between the production site, the maintenance staff, and the management office. And the progress of maintenance work in response to a request from the production site can be grasped at a glance, and the work efficiency of maintenance staff who maintain the production equipment can be improved.
- FIGS. 9A to 9G are explanatory diagrams showing display examples indicating maintenance requests, support requests, replacement requests, maintenance start, maintenance interruption, and maintenance completion.
- FIG. 10A is an explanatory diagram illustrating an example of a maintenance status list for each facility (maintenance start), and FIG. 10B is an explanatory diagram illustrating an example of a maintenance status list for each facility (maintenance suspension).
- FIG. 11A is an explanatory diagram showing an example of the maintenance status list by facility (maintenance restart), and FIG. 11B is an explanatory diagram showing an example of the maintenance status list by facility (completion of correspondence).
- the facility maintenance support system 10 includes one or more maintenance staff offices 12, one or more production staff offices 14, a plurality of production lines 16, and a plurality of warehouses 18, as shown in FIG. Applicable to normal production plant.
- the equipment maintenance support system 10 includes at least one server, one or more terminals, and one or more management monitors as needed for each of the maintenance staff office 12, the production staff office 14, and the production line 16. Are arranged.
- the maintenance staff office 12 has a maintenance management server 20.
- the maintenance management server 20 includes a maintenance staff terminal 22 for each maintenance staff, a barcode printer 24 that issues an identification sheet (sheet with a barcode printed on the surface) to be affixed to maintenance parts, and a maintenance management monitor. 26 is connected.
- the maintenance staff terminal 22, the barcode printer 24 and the maintenance management monitor 26 are connected to the maintenance management server 20 through an internal bus 28.
- the production staff office 14 is provided with a production management monitor 30.
- the production staff office 14 may also have a production management server and a production staff terminal for each production staff.
- Each call line 32 is installed in each production line 16.
- each production line 16 is provided with an equipment monitoring system 38 that monitors the operation status of one or more equipments arranged on the production line 16 using the sensor 36 or the like.
- the maintenance staff terminal 22 a notebook type or desktop type information terminal placed on a desk or the like, a portable information terminal capable of performing screen display, and the like can be cited.
- the maintenance management server 20 and the call terminal 32 of each production line 16 are connected to each other through an external bus 40. Accordingly, data is transmitted and received among the maintenance management server 20, the maintenance staff terminal 22, and the call terminal 32.
- the maintenance staff terminal 22 is connected to a barcode reader 42 for reading a barcode (identified simply as a barcode) of an identification sheet attached to each maintenance component.
- a barcode reader 42 for reading a barcode (identified simply as a barcode) of an identification sheet attached to each maintenance component.
- data transmission / reception among the maintenance management server 20, the maintenance staff terminal 22, and the call terminal 32 may be performed wirelessly.
- the maintenance management server 20 has a backbone system (for example, an operating system) including a program related to a preventive maintenance plan and production maintenance system data.
- the maintenance management server 20 provides files and data in accordance with requests from various terminals (clients).
- the functional units included in the call terminal 32 include a maintenance plan display processing unit 50, an equipment layout display processing unit 52, a first maintenance request processing unit 54A, a first support request processing unit 56A, a second A support request processing unit 56B, a change request processing unit 58, a maintenance start processing unit 60, a maintenance interruption processing unit 62, a maintenance restart processing unit 64, a maintenance completion processing unit 66, and a maintenance support information display processing unit 68 are provided.
- the facility monitoring system 38 includes a second maintenance request processing unit 54B.
- the maintenance support information display processing unit 68 includes a support / replacement request screen display processing unit 70, an equipment operation status history display processing unit 72, a maintenance work status display processing unit 74, and a repair parts list display processing unit 76. , An inventory search screen display processing unit 78, a work completion registration screen display processing unit 80, a maintenance history list display processing unit 82, and a detailed history display processing unit 84.
- the maintenance staff terminal 22 is a portable terminal, the maintenance staff can carry the maintenance work by carrying the maintenance staff terminal 22. In this case, the maintenance staff terminal 22 can also be used as the call terminal 32.
- a display 32a is connected to the call terminal 32.
- the display 32a includes at least an equipment main screen 90 (see FIG. 4), a maintenance plan screen 92 (see FIG. 5), and an equipment layout.
- a screen 94 (see FIG. 8) and the like are displayed.
- the facility main screen 90 includes a button display area 100 in which various buttons are arranged, a message display area 102 in which a message is displayed, and the like.
- the button display area 100 includes, for example, a maintenance request button 104, a consultation request button 106, a plan start button 108, a response completion button 110, and the like.
- the maintenance request button 104 and the consultation request button 106 are respectively a mechanical maintenance request button 104a and a mechanism consultation request button 106a that are operated in the case of a mechanical system failure, and an electrical maintenance request button that is operated in the case of an electrical system failure. 104b and an electric consultation request button 106b.
- mechanical system failures and consultations include abnormal motor noise, chain breakage, air leakage, and oil leakage.
- electrical system failures and consultations include sensor failures, damp stop (no alarm line stop), electrical equipment failures, and so on.
- the maintenance request button 104 includes a maintenance start / resume button 104c that is operated when maintenance work (including maintenance work by consultation) is started or resumed, and a maintenance interruption button that is operated when maintenance work is interrupted. 104d.
- the plan start button 108 is operated by a maintenance staff on a preset maintenance plan date (such as the beginning of the fiscal year), thereby starting the maintenance plan display processing unit 50 (see FIG. 2).
- the maintenance plan display processing unit 50 displays a maintenance plan screen 92 of the equipment on the display 32a and the production management monitor 30 (hereinafter referred to as the display 32a).
- the maintenance plan screen 92 includes, for example, a part replacement schedule, a driving part check schedule, and the like. Then, the maintenance staff carries out planned maintenance for the planned equipment among the displayed maintenance plans.
- the equipment main screen 90 has three tabs (first tab 120a to third tab 120c) as shown in FIG.
- first tab 120a By operating the first tab 120a, the equipment main screen 90 is displayed, and by operating the second tab 120b, a pull-down menu (not shown) regarding the production support tool is displayed.
- second tab 120b By operating the third tab 120c, a pull-down menu 122 relating to the maintenance activity support tool is displayed as shown in FIG.
- This pull-down menu 122 has a display form in which a plurality of items for supporting maintenance activities are arranged, for example.
- the support / change request screen display processing unit 70 By selecting and operating the first item (first item) from above, the support / change request screen display processing unit 70 (see FIG. 3) is activated.
- the support / replacement request screen display processing unit 70 displays a support / replacement request screen 124 as shown in FIG.
- the support / change request screen 124 includes a support request button 126 and a change request button 128.
- the support request button 126 and the change request button 128 include a mechanism support request button 126a and a mechanism change request button 128a that are operated in the case of a mechanical system failure, respectively, and an electric support request button that is operated in the case of an electrical system failure. 126b and an electric change request button 128b.
- Equipment main screen 90 For example, a mechanical maintenance request button 104a, an electrical maintenance request button 104b, a mechanical consultation request button 106a, an electrical consultation request button 106b on the equipment main screen 90 (see FIG. 4), and a mechanical support request on the support / replacement request screen 124 (see FIG. 7).
- the equipment layout display processing unit 52 By operating any of the button 126a, the electric support request button 126b, the mechanical change request button 128a, and the electric change request button 128b, the equipment layout display processing unit 52 (see FIG. 2) is activated.
- the equipment layout display processing unit 52 displays an equipment layout screen 94 as shown in FIG.
- the equipment layout display processing unit 52 requests the maintenance management server 20 to transfer image data of the equipment layout screen 94 or additional information according to various requests and various work progresses.
- the facility layout screen 94 is displayed based on the image data or additional information transferred from the maintenance management server 20.
- the equipment layout screen 94 includes an image 130 simulating a plan view of a production site, a schematic diagram 132 of a plurality of production lines 16, and a plurality of productions arranged for each production line 16.
- the form etc. which displayed the symbol image 134 which shows an installation are mentioned.
- a red circle 136R is displayed on the right shoulder of the symbol image 134 of the requested facility. If it is a system maintenance request, for example, a yellow circle 136Y is displayed as shown in FIG. 9B.
- a circular 136rw for example, a left part of the symbol image 134 of the requested facility, for example, red on the right shoulder
- a circular 136yw for example, the left semicircle is partially yellow
- a green circle 136G is displayed on the right shoulder of the symbol image 134 of the requested equipment
- maintenance is interrupted, as shown in FIG. 9F
- a light blue circle 136A is displayed on the right shoulder of the symbol image 134 of the requested facility
- a circular display displayed on the right shoulder of the symbol image 134 of the requested facility, for example. Is erased. Note that nothing is displayed on the right shoulder of the symbol image 134 of the requested facility as shown in FIG. 9G for normal production facilities that have not been requested for maintenance.
- the display of red circles and yellow circles displayed in response to the mechanical system maintenance request, electrical system maintenance request, etc. described above is merely an example, depending on the environment such as the factory where the equipment maintenance support system is installed. Can be set as appropriate.
- the production staff or the like operates, for example, the mechanical maintenance request button 104a, the electrical maintenance request button 104b, the mechanical consultation request button 106a, or the electrical consultation request button 106b on the equipment main screen 90 (see FIG. 4), and the equipment layout screen 94 ( After displaying (see FIG. 8), the first maintenance request processing unit 54A (see FIG. 2) can display the symbol image 134 indicating the production facility subject to the maintenance request by touching with a finger or a pen-like instrument. It is activated.
- the first maintenance request processing unit 54A makes a mechanical or electrical maintenance request. That is, the maintenance request information is transmitted to the maintenance management server 20 and the maintenance staff terminal 22.
- the maintenance request information includes, for example, a maintenance request code, a transmission source code, a mechanical system or electrical system type, and an equipment code.
- the first maintenance request code is an identification code for recognizing the maintenance request information in the maintenance management server 20 and each terminal. The same applies hereinafter.
- the identification code of the call terminal 32 that is the transmission source is used.
- equipment code equipment identification information associated with the call terminal 32 on a one-to-one basis is used. In this case, the identification information of the requested equipment is used.
- the identification information of the requested equipment is used when a maintenance person who arrives at the requested equipment outputs information on at least parts and maintenance history related to the contents of the maintenance request to the display 32a of the call terminal 32 or the like.
- Examples of information related to parts and maintenance history include parts necessary for maintenance and storage locations of the parts, information related to troubles that occurred in the past, information related to comments from maintenance staff regarding the troubles that occurred in the past, and the like.
- the identification information of the requested equipment is information relating to these pieces of information (information relating to parts and maintenance history) and is used as key information for outputting these pieces of information.
- the second maintenance request processing unit 54B is incorporated in the equipment monitoring system 38 as shown in FIG.
- the second maintenance request processing unit 54B is activated based on the input of a signal notifying the abnormality from the sensor 36 that monitors the operation status of the equipment arranged on the production line 16, and confirms that the maintenance request has been made in the equipment.
- mechanical or electrical classification information may be included according to the type of the sensor 36.
- the production staff or the like selects and operates the first item of the pull-down menu 122 (see FIG. 6), thereby starting up the support / change request screen display processing unit 70 (see FIG. 2).
- the support / change request screen display processing unit 70 displays a support / change request screen 124 (see FIG. 7) on the display 32 a of the call terminal 32.
- the first support request processing unit 56A (see FIG. 2) is activated by touching with a finger or touching with a pen-like instrument.
- the first support request processing unit 56A makes a mechanical support request or an electrical support request. That is, the first support request information is transmitted to the maintenance management server 20 and the maintenance staff terminal 22.
- the first support request information includes, for example, a first support request code, a transmission source code, a mechanical system or electrical system type, an equipment code, and the like.
- the first first support request code is an identification code for recognizing the first support request information (support request by the staff) in the maintenance management server 20 and each terminal. Since the transmission source code and the like are the same as the above-described maintenance request information, a duplicate description thereof is omitted.
- the first support request is made in the following cases, for example. In other words, depending on the situation of the requested equipment or the like, it may be more efficient to work by a plurality of people. In addition, there are cases where the requested facility is a facility (power supply device, compressor, etc.) that is highly important in the production of products, and early repair completion is required. In such a case, the maintenance staff requests support (staff).
- a maintenance request or consultation when a maintenance request or consultation is made, it is determined that a mechanical failure has occurred (primary determination), and a maintenance request or consultation is made by operating the mechanism maintenance request button 104a or the mechanism consultation request button 106a. If the result of the determination (secondary determination) indicates that the failure is not related to mechanical but related to electricity, a support request from a maintenance person or the like is made. A support request is also made when the primary determination is an electrical failure and the secondary determination is a mechanical failure.
- the second support request processing unit 56B (see FIG. 2) is activated when a predetermined time (for example, 90 minutes, 120 minutes, etc.) has passed since the maintenance staff was dispatched.
- the second support request processing unit 56B makes a support request for mechanical or electrical relations. That is, the second support request processing unit 56B transmits the second support request information to the maintenance management server 20 and the maintenance staff terminal 22.
- the second support request information includes, for example, a second support request code, a transmission source code, a mechanical system or electrical system type, an equipment code, and the like. As the type of the mechanical system or the electrical system, the type used in the maintenance request information is used.
- the 2nd support request processing part 56B outputs the alarm which shows abnormality of maintenance work with a support request.
- the replacement request information includes, for example, a replacement request code, a transmission source code, a mechanical system or electrical system type, and an equipment code.
- the head replacement request code is an identification code for recognizing that the maintenance management server 20 and each terminal are replacement request information (a replacement request by a staff member). Since the transmission source code and the like are the same as the above-described maintenance request information, a duplicate description thereof is omitted.
- a maintenance staff requests for example in the message display area 102 of the equipment main screen 90 (see FIG. 4). A message is displayed indicating that you are moving to the facility.
- the replacement request is made, for example, in the following cases. That is, for example, when a maintenance request or consultation is made, it is determined that a mechanical failure has occurred (primary determination) and the maintenance request or consultation is performed by operating the mechanical maintenance request button 104a or the mechanical consultation request button 106a. If the result of the determination (secondary determination) indicates that the failure is not related to the mechanical but electrical, a replacement request is made by a maintenance person or the like. A replacement request is also made when the primary judgment is an electrical fault and the secondary judgment is a mechanical fault.
- the maintenance person who has arrived at the requested equipment operates the maintenance start / resume button 104c on the equipment main screen 90 (see FIG. 4) to activate the maintenance start processing unit 60 (see FIG. 2).
- the maintenance start processing unit 60 notifies the maintenance management server 20 that a maintenance start has been made by a maintenance person. That is, the maintenance start processing unit 60 creates maintenance start information and transmits it to the maintenance management server 20.
- the maintenance start information includes, for example, a maintenance start code, a transmission source code, a person-in-charge code, an equipment code, and the like.
- the facility-specific maintenance status list 140 is displayed on the display 32a of the call terminal 32.
- the maintenance status list 140 by facility mainly includes the date and time when the maintenance request was made (request date), the name of the equipment, the status when the maintenance request was made (status at the time of request), the current status, Stop time (minutes) is displayed. As the current situation, “moving” indicating that the maintenance staff was moving toward the requested equipment is displayed.
- the maintenance person in charge operates the maintenance interruption button 104d (see FIG. 4) on the equipment main screen 90, whereby the maintenance interruption processing unit 62 (see FIG. 2) is activated.
- the maintenance interruption processing unit 62 notifies the maintenance management server 20 that there has been a maintenance interruption by a maintenance person in charge. That is, the maintenance interruption processing unit 62 creates maintenance interruption information and transmits it to the maintenance management server 20.
- the maintenance interruption information includes, for example, a maintenance interruption code, a transmission source code, a person in charge code, an equipment code, and the like.
- the facility-specific maintenance status list 140 is displayed on the display 32a of the call terminal 32.
- “Now working” is displayed indicating that the maintenance staff is performing maintenance work, and further, for example, a symbol indicating “Suspended” is displayed at the right end. .
- the maintenance restart processing unit 64 notifies the maintenance management server 20 that maintenance has been restarted by the maintenance staff. That is, the maintenance restart processing unit 64 creates maintenance restart information and transmits it to the maintenance management server 20.
- the maintenance restart information includes, for example, a maintenance restart code, a transmission source code, a person-in-charge code, an equipment code, and the like.
- a facility-specific maintenance status list 140 is displayed on the display 32a of the call terminal 32.
- “corresponding suspension” indicating that the maintenance work has been interrupted is displayed, and further, for example, a symbol display indicating “resume” is performed at the right end.
- the maintenance completion processing unit 66 When the maintenance person operates the response completion button 110 (see FIG. 4) on the equipment main screen 90, the maintenance completion processing unit 66 (see FIG. 2) is activated.
- the maintenance completion processing unit 66 notifies the maintenance management server 20 that the maintenance response has been completed by the maintenance staff. That is, the maintenance completion processing unit 66 creates maintenance completion information and transmits it to the maintenance management server 20.
- the maintenance completion information includes, for example, a maintenance completion code, a transmission source code, a person in charge code, an equipment code, and the like.
- the equipment-specific maintenance status list 140 is displayed on the display 32a of the call terminal 32.
- “in response” is displayed, indicating that the maintenance staff was performing maintenance work.
- the equipment operation status history display processing unit 72 By selecting and operating the second item in the pull-down menu 122 of FIG. 6, the equipment operation status history display processing unit 72 (see FIG. 3) is activated.
- the facility operation status history display processing unit 72 displays a facility operation status history screen 144 on the display 32a as shown in FIG.
- the equipment operation status history screen 144 mainly includes a production line name input field 146a, an equipment name input field 146b, a search button 146c, and the like. Then, a maintenance person or the like inputs the production line name in the production line name input field 146a, the equipment name in the equipment name input field 146b, and touches the search button 146c with a finger or a pen-like instrument, etc.
- the equipment operating status history display processing unit 72 displays the operating status history of the corresponding equipment.
- the contents displayed in the history include the contents of the event that has occurred and the time at which the event occurred.
- the maintenance work status display processing unit 74 (see FIG. 3) is activated by selecting and operating the third item in the pull-down menu 122 of FIG. As shown in FIG. 13, the maintenance work status display processing unit 74 displays a maintenance facility work status list screen (referred to as an all-line monitor screen) 148 on the display 32a.
- This all-line monitor screen 148 mainly displays a list of the current work status of facilities requested for maintenance among all the production lines.
- the breakdown includes the time when the maintenance request is made (request time), the elapsed time of the operation stop state (stop / elapsed time), the production line name, the equipment name, the current work status, the name of the person in charge of maintenance, and the like.
- facilities that are in maintenance are displayed in red, for example, and other facilities are displayed in blue, for example, so that the facilities that are in maintenance can be easily identified.
- the repair parts list display processing unit 76 By selecting and operating the fourth item in the pull-down menu 122 of FIG. 6, the repair parts list display processing unit 76 (see FIG. 3) is activated.
- the repair part list display processing unit 76 displays a repair part search screen 150 on the display 32a as shown in FIG.
- the repair part search screen 150 mainly has a list display area 152a and a drawing display area 152b.
- the list display area 152a displays the type and part name of the repair part in a list format.
- an appearance, a perspective view, and the like of a repaired part selected by a selection input (selection input by a pointer, touch, etc.) to the list display area 152a are displayed.
- the inventory search screen display processing unit 78 By selecting and operating the fifth item in the pull-down menu 122 of FIG. 6, the inventory search screen display processing unit 78 (see FIG. 3) is activated.
- the inventory search screen display processing unit 78 displays an inventory search screen 154 on the display 32a as shown in FIG.
- the inventory search screen 154 mainly includes a repair parts type input field 156a, a part name input field 156b, a repair parts list screen 156c, a search button 156d, and a plurality of warehouses storing repair parts.
- An arrangement screen 156e or the like indicating the position of is displayed.
- the repair parts list screen 156c The breakdown of the repair parts to be obtained is displayed, and the position of the warehouse where the repair parts to be obtained are stored is displayed on the arrangement screen 156e.
- a number indicating the location of the warehouse is indicated by, for example, red display or flashing display.
- the maintenance staff When obtaining repair parts, for example, the maintenance staff interrupts the maintenance work and obtains repair parts from the corresponding warehouse, or sends information on repair parts to other maintenance staff (model, part name, warehouse location, etc.) ) And ask them to arrange repair parts.
- the work completion registration screen display processing unit 80 (see FIG. 3) is activated by selecting and operating the sixth item of the pull-down menu 122 shown in FIG.
- the work completion registration screen display processing unit 80 first displays the facility-specific maintenance status list 140 (see FIG. 11B) on the display 32a.
- this maintenance status list 140 by facility, mainly the date and time when the maintenance request was made (request date and time), the name of the facility, the status when the maintenance request was made (status at the time of request), the current status, and the downtime (Minutes) etc. are displayed.
- the work completion registration screen display processing unit 80 displays a work completion registration screen 158 for each person in charge as shown in FIG. To do.
- the person-in-charge work completion registration screen 158 the person-in-charge name, reception time, start time, and response time are mainly displayed for each person in charge.
- the work completion registration screen display processing unit 80 displays a message indicating that correspondence completion has been registered for each person in charge. At this stage, the work completion registration for each person in charge is completed.
- the maintenance history list display processing unit 82 By selecting and operating the seventh item of the pull-down menu 122 in FIG. 6, the maintenance history list display processing unit 82 (see FIG. 3) is activated.
- the maintenance history list display processing unit 82 displays a maintenance history list screen 160 as shown in FIG.
- the maintenance history list screen 160 mainly has an item input area 162a and a history list display area 162b.
- the item input area 162a since the history list has a huge amount of information, the item input area 162a can be displayed by narrowing down by, for example, the period, model name, line name, and facility name. Examples of items for narrowing down include a period, model name, line name, equipment name, creation status, history type, and the like.
- the maintenance history list display processing unit 82 requests the maintenance management server 20 to transfer the history information of the corresponding equipment. Based on the above transfer request from the call terminal 32, the maintenance management server 20 reads the maintenance history of the corresponding equipment from a maintenance history database 198 (see FIG. 19), which will be described later, and transmits it to the requested call terminal 32. To do.
- the maintenance history list display processing unit 82 receives the maintenance history data from the maintenance management server 20, and displays the contents in the history list display area 162b (see FIG. 17).
- the history list display area 162b mainly includes a production line name, equipment name, history type (sudden failure, consultation / plan distinction), occurrence date / time, maintenance person name, downtime, history, remarks, etc. in a list format. Is displayed.
- the line whose type is “sudden failure” is displayed in red and the consultation / planning line is displayed in blue, for example, so that it can be easily distinguished. It has become.
- the maintenance history list screen 160 has a history display button 164 for displaying a maintenance history detail screen 170 (see FIG. 18).
- the history display button 164 is touched with a finger or touched with a pen-like instrument, the detailed history display processing unit 84 (see FIG. 3) is activated.
- the detailed history display processing unit 84 displays a maintenance history detail screen 170 (see FIG. 18) for inputting a detailed history.
- the maintenance history detail screen 170 includes items that are automatically input by the system such as department, equipment name, occurrence date and time, and stop time, and items that are input by maintenance staff in charge of events, causes, measures, and the like.
- the maintenance staff does not need to input the department or equipment name, but can input the event, the cause, the treatment, and the like, so that the input time can be shortened.
- the maintenance management server 20 registers the maintenance history data from the requested equipment in the maintenance history database 198 (see FIG. 19).
- the maintenance management server 20 includes a request progress reception unit 180, a request reflection unit 182, a work progress reflection unit 184, a maintenance history management unit 186, a maintenance management screen display processing unit 188, The repair part reflecting unit 190, the request temporary storage file 192, and the work progress temporary storage file 194 are provided. Further, a maintenance history database 198 and a repair parts database 200 are connected to the maintenance management server 20.
- the request progress accepting unit 180 performs various maintenance requests such as a first maintenance request from the call terminal 32, a second maintenance request from the equipment monitoring system 38, a support request from the call terminal 32, a replacement request, and the like. Accepts work progress information such as maintenance restart.
- the request reflecting unit 182 registers various requests received by the request progress receiving unit 180 in the request temporary storage file 192 and further registers in the maintenance history database 198.
- the request reflection unit 182 reflects various requests registered in the request temporary storage file 192 on the equipment layout screen 94 (see FIG. 8).
- a red circle 136R (see FIG. 9A) is displayed on the right shoulder of the symbol image 134 of the requested facility, and if it is an electrical system maintenance request, a yellow circle is displayed. Additional information or the like for displaying 136Y (see FIG. 9B) is transmitted to all terminals to share the information.
- the request reflection unit 182 may be, for example, a circular 136rw (see FIG. 9C) in which a part of the symbol image 134 of the requested facility is red on the right shoulder, for example, if the request is for a mechanical support or replacement request for the requested facility. If it is an electrical support request or a change request, additional information displaying a circular 136yw (see FIG. 9D) partially yellow is transmitted to all terminals to share the information. Of course, you may transmit the image data of the equipment layout screen 94 in which additional information was reflected.
- the work progress reflecting unit 184 registers the various work progress information received by the request progress receiving unit 180 in the work progress temporary storage file 194 and further registers it in the maintenance history database 198.
- the work progress reflecting unit 184 reflects various work progresses registered in the work progress temporary storage file 194 on the equipment layout screen 94 (see FIG. 8).
- a green circle 136G (see FIG. 9E) is displayed on the right shoulder of the symbol image 134 of the requested facility, for example.
- a light blue circle 136A (see FIG. 9F) is displayed on the right shoulder, and if maintenance is complete, as shown in FIG. 9G, the circular image displayed on the right shoulder, for example, of the symbol image 134 of the requested facility is deleted.
- the work progress information is maintenance completion
- information such as a maintenance request and a support request registered in the request temporary storage file 192 and the work progress temporary storage file 194 is deleted with respect to the requested equipment that has undergone maintenance completion. .
- the maintenance history management unit 186 transmits the information stored in the request temporary storage file 192 and the work progress temporary storage file 194 to the requested terminals (call terminal 32, maintenance staff terminal 22, etc.). Thereby, in each call terminal 32, each maintenance staff terminal 22, etc., the request status and work progress status in each equipment are reflected in the equipment layout screen 94, equipment operation status history screen 144, all line monitor screen 148, etc.
- the maintenance history management unit 186 stores the maintenance history information transmitted from the call terminal 32 or the maintenance staff terminal 22, that is, various information input to the maintenance history detail screen 170 in the maintenance history database 198.
- the maintenance management screen display processing unit 188 displays a multi-screen 202 including an equipment layout screen 94 and an all-line monitor screen 148 on the maintenance management monitor 26 as shown in FIG. Thereby, the maintenance status at the requested equipment of each production line 16 can be confirmed at a glance by the text information and the image information.
- the above-described request progress receiving unit 180 registers the information of the person in charge of maintenance from the maintenance staff terminal 22 in the maintenance history database 198, the request temporary storage file 192, and the work progress temporary storage file 194. .
- the request progress receiving unit 180 transmits information for displaying a message (name of the person in charge of maintenance, person in charge code, etc.) to the call terminal 32 of the requested facility.
- the repair part reflection unit 190 reflects information such as the number of repair parts used, which is input by the delivery process at the maintenance staff terminal 22, for example, in the repair part database 200.
- the maintenance staff terminal 22 displays a request receiving unit 210 that receives various requests from the call terminal 32 and the like, and a staff current status screen 212 (see FIG. 22) showing the current status of the maintenance staff.
- the maintenance staff terminal 22 has an equipment layout display processing unit 52. Therefore, the facility layout screen 94 reflecting the maintenance request or the like can be displayed on the display 22a and the maintenance management monitor 26.
- the multi-screen 202 from the maintenance management server 20 is displayed on the maintenance management monitor 26, but an equipment layout screen 94 from the maintenance staff terminal 22 can also be displayed.
- the request receiving unit 210 receives various requests such as a first maintenance request from the call terminal 32, a second maintenance request from the equipment monitoring system 38, a support request from the call terminal 32, and a replacement request.
- the staff current status screen 212 is divided into a mechanical charge area 220a and an electrical charge area 220b.
- the mechanical charge area 220a the same number of rectangular blocks 222 as the number of mechanical charge staff members are displayed.
- the electric charge area 220b the same number of rectangular blocks 222 as the number of electric charge staff members are displayed.
- the display color of the block 222 is displayed in green if currently waiting, and is displayed in gray if maintenance work is in progress (including support and change).
- a maintenance person is selected from the maintenance staff corresponding to the block 222 displayed in green. That is, the maintenance staff on standby is contacted in advance, and when the consent is obtained, the maintenance staff is requested to be dispatched, and the maintenance staff block 222 selected this time on the staff status screen 212 is pointed with a finger. Touch or touch with a pen-like instrument. As a result, the maintenance person notifying unit 216 is activated and transmits information (person in charge code, etc.) of the maintenance person corresponding to at least the selected block 222 to the maintenance management server 20.
- the request progress reception unit 180 (see FIG. 19) of the maintenance management server 20 displays the notified maintenance staff information and the received time (outgoing time), the maintenance history database 198, the request temporary storage file 192, and the work progress temporary storage. Register in file 194.
- the delivery processing unit 208 (see FIG. 21) of the maintenance staff terminal 22 is activated together with the inventory search screen display processing unit 78 (see FIG. 3) by selecting and operating the fifth item of the pull-down menu 122 in FIG.
- the inventory search screen display processing unit 78 displays an inventory search screen 154 on the display 22a as shown in FIG.
- the maintenance person in charge performs input by subtracting the number of parts replaced from the stock quantity in the column corresponding to the model, part name, and storage location of the repaired part replaced.
- the exit processing unit 208 transmits the input information to the maintenance management server 20.
- the repair part reflection unit 190 (see FIG. 19) of the maintenance management server 20 receives the information from the delivery processing unit 208 and reflects the input inventory number in the repair part database 200. As a result, the actual inventory quantity in the warehouse 18 and the inventory quantity as data registered in the repair parts database 200 coincide.
- step S1 of FIG. 23 it is determined whether or not there is a maintenance request. Specifically, the call terminal 32 determines whether there is a first maintenance request, and the facility monitoring system 38 determines whether there is a second maintenance request.
- step S2 the maintenance plan display processing unit 50 determines whether the maintenance plan is confirmed or the maintenance work is based on the maintenance plan. This determination is made based on whether or not the planned start button 108 on the equipment main screen 90 (see FIG. 4) has been operated.
- step S3 When the operation of the plan start button 108 on the equipment main screen 90 is performed, the process proceeds to step S3, and the maintenance plan screen 92 (see FIG. 5) is displayed on the display 32a of the call terminal 32 or the like.
- step S4 the maintenance staff carries out planned maintenance for the target equipment in the displayed maintenance plan.
- step S4 When the process in step S4 is completed, or when it is determined in step S2 that the planned start button 108 is not operated, the process returns to step S1, and the processes after step S1 are repeated.
- step S1 If it is determined in step S1 that there is a first maintenance request from the call terminal 32 or a second maintenance request from the equipment monitoring system 38, the process proceeds to step S5, where the maintenance management server 20 and the maintenance staff terminal 22 accepts a first maintenance request from the call terminal 32 or a second maintenance request from the equipment monitoring system 38.
- the request reflection unit 182 of the maintenance management server 20 registers the first maintenance request or the second maintenance request in the request temporary storage file 192 and the maintenance history database 198. Further, the first maintenance request or the second maintenance request is reflected on the facility layout screen 94 (see FIG. 8) of the call terminal 32, the maintenance staff terminal 22, and the like.
- step S6 the maintenance staff appoints a maintenance person based on the first maintenance request from the call terminal 32 or the second maintenance request from the equipment monitoring system 38 while looking at the staff status screen 212 (see FIG. 22), for example.
- the maintenance staff terminal 22 transmits to the maintenance management server 20 information on a maintenance person appointed in response to the first maintenance request or the second maintenance request.
- step S7 the selected maintenance staff dispatches to the requested equipment.
- the request progress reception unit 180 of the maintenance management server 20 registers the information of the person in charge of maintenance from the maintenance staff terminal 22 in the maintenance history database 198 and transmits it to the call terminal 32 of the requested equipment.
- a message indicating that the maintenance staff is moving to the requested facility is displayed in the message display area 102 of the facility main screen 90 (see FIG. 4) of the call terminal 32 of the requested facility.
- step S8 the maintenance person who has arrived at the requested facility operates the start / resume button 104c (see FIG. 4), so that the maintenance work starts.
- the call terminal 32 notifies the maintenance management server 20 that maintenance has been started by the maintenance staff.
- the maintenance management server 20 receives information related to the maintenance start from the call terminal 32.
- the work progress reflecting unit 184 registers the work progress information indicating the maintenance start in the work progress temporary storage file 194 and the maintenance history database 198. Further, the fact that maintenance has started is reflected in the equipment layout screen 94 (see FIG. 8) of the call terminal 32, the maintenance staff terminal 22, and the like.
- step S9 of FIG. 24 the call terminal 32 determines whether or not the maintenance work is interrupted. This determination is made based on whether or not the maintenance interruption button 104d (see FIG. 4) on the equipment main screen 90 has been operated. If the maintenance work is interrupted, the process proceeds to step S10, and the call terminal 32 informs the maintenance management server 20 that the maintenance person has interrupted the maintenance.
- the maintenance management server 20 receives information regarding maintenance interruption from the call terminal 32.
- the work progress reflecting unit 184 registers work progress information indicating maintenance interruption in the work progress temporary storage file 194 and the maintenance history database 198. Further, the fact that the maintenance has been interrupted is reflected on the equipment layout screen 94 (see FIG. 8) of the call terminal 32, the maintenance staff terminal 22, and the like.
- step S11 the call terminal 32 determines whether or not the maintenance interruption is a support request. This determination is made based on whether or not the support request button 126 on the support / change request screen 124 (see FIG. 7) has been operated. If it is a support request, it will progress to step S12 and the call terminal 32 will notify the maintenance management server 20 that the support person in charge had the support request.
- the maintenance management server 20 receives information related to a support request from the call terminal 32.
- the request reflection unit 182 registers information related to the support request in the request temporary storage file 192 and the maintenance history database 198. Further, the request for support is reflected in the equipment layout screen 94 (see FIG. 8) of the call terminal 32, the maintenance staff terminal 22, and the like.
- step S11 If it is determined in step S11 that the request is not a support request, the process proceeds to step S13, and the call terminal 32 determines whether the maintenance interruption is due to a replacement request. This determination is made based on whether or not the change request button 128 on the support / change request screen 124 (see FIG. 7) has been operated. If it is a replacement request, the process proceeds to step S14, and the call terminal 32 notifies the maintenance management server 20 that a replacement request has been made by the maintenance staff.
- the maintenance management server 20 receives information related to the change request from the call terminal 32.
- the request reflection unit 182 registers information regarding the replacement request in the request temporary storage file 192 and the maintenance history database 198. Further, the request for replacement is reflected on the equipment layout screen 94 (see FIG. 8) of the call terminal 32, the maintenance staff terminal 22, and the like.
- step S15 When the process in step S12 or step S14 is completed, or when it is determined in step S13 that it is not a replacement request, for example, when it is an interruption due to a break or the like of a maintenance person, the process proceeds to step S15.
- the call terminal 32 determines whether or not maintenance is resumed. This determination is made based on whether or not the maintenance start / resume button 104c on the equipment main screen 90 (see FIG. 4) has been operated. If the maintenance work is to be resumed, the process proceeds to step S16, and the call terminal 32 notifies the maintenance management server 20 that the maintenance person has resumed the maintenance.
- the maintenance management server 20 receives information related to maintenance resumption from the call terminal 32.
- the work progress reflecting unit 184 registers work progress information indicating maintenance resumption in the work progress temporary storage file 194 and the maintenance history database 198. Furthermore, the fact that maintenance has been resumed is reflected in the equipment layout screen 94 (see FIG. 8) of the call terminal 32, the maintenance staff terminal 22, and the like.
- step S16 When the process in step S16 is completed or when it is determined in step S9 that the maintenance work is not interrupted, the process proceeds to the next step S17, and the call terminal 32 determines whether or not the maintenance work is completed. Is determined. This determination is made based on whether or not the operation of the response completion button 110 on the equipment main screen 90 (see FIG. 4) has been performed. If the maintenance work is completed, the process proceeds to step S18, and the call terminal 32 notifies the maintenance management server 20 that the maintenance person has completed the maintenance.
- the maintenance management server 20 receives information related to maintenance completion from the call terminal 32.
- the work progress reflecting unit 184 registers work progress information indicating completion of maintenance in the work progress temporary storage file 194 and the maintenance history database 198. Further, the completion of the maintenance is reflected on the equipment layout screen 94 (see FIG. 8) of the call terminal 32, the maintenance staff terminal 22, and the like.
- step S19 the maintenance person or the like performs a delivery process.
- the repair part reflection unit 190 (see FIG. 19) reflects information such as the number of repair parts used, which is input by the delivery process at the maintenance staff terminal 22, for example, in the repair part database 200.
- step S20 the maintenance person creates a history of the current maintenance work and updates the maintenance history. That is, for example, after the maintenance history list screen 160 (see FIG. 17) is displayed on the display 22a of the maintenance staff terminal 22, the requested equipment in charge is selected and the history display button 164 is operated, thereby maintaining the maintenance history of the requested equipment. A detail screen 170 (see FIG. 18) is displayed. Then, input the event, cause, and treatment of the requested equipment, and if there are replacement parts that have been replaced, enter the type, part name, shipping location, quantity used, etc. Of course, regarding the input of the replaced repair part, the input may be omitted by associating it with the previously issued shipping process.
- the facility maintenance support system 10 includes a request progress reception unit 180 that receives a maintenance request from the call terminal 32 arranged in the production line 16, and at least a maintenance request among a plurality of maintenance staff. Based on the contents of the maintenance staff and the current status of a plurality of maintenance staff, a maintenance request according to the staff status display processing unit 214 used for selecting a maintenance staff in accordance with the maintenance request and the request of the selected maintenance staff.
- a maintenance support information display processing unit 68 for outputting at least parts and maintenance history information related to the contents as maintenance support information.
- maintenance staff office 12 information can be shared using communication means between the production site, maintenance staff, and the management office (maintenance staff office 12). It is possible to grasp at a glance the progress of the maintenance work in response to the request, and it is possible to improve the work efficiency of the maintenance staff that maintains the production equipment.
- maintenance work can proceed smoothly, and past maintenance history can be used to report on this maintenance work. Reporting stagnation can also be resolved. For example, at the start of maintenance work, the history of maintenance contents, replacement parts, past records of related personnel, etc. are presented as a maintenance history. This maintenance history can be used as meaningful information for maintenance personnel to consider trouble improvement, so maintenance work can be carried out efficiently, and maintenance work can be carried out with reduced equipment downtime. be able to.
- an equipment layout display processing unit 52 that displays an equipment layout screen 94 indicating the location of one or more production equipment installed at a production site on at least the maintenance management monitor 26 and the call terminal 32;
- a request reflecting unit 182 that reflects the request from the line 16 on the equipment layout screen 94 and a work progress reflecting unit 184 that reflects the progress of maintenance work by the maintenance staff on the equipment layout screen 94 are provided.
- the maintenance request includes at least primary determination information indicating whether it is a mechanical trouble or an electric trouble.
- the maintenance request is made by the production staff in a state where an equipment layout screen 94 showing the location of one or more production equipment installed at the production site is displayed on the call terminal 32 arranged on the production line 16. This is done manually. As a result, since the maintenance request is reflected on the equipment layout screen 94, the production staff makes a maintenance request while viewing the equipment layout screen 94, so that the maintenance request is correctly made to the equipment requiring the maintenance request. Can be easily confirmed.
- the maintenance request manually input by the production staff includes at least information on the parts necessary for maintenance and the storage location of the parts.
- the maintenance request includes information on the parts required for maintenance and the storage location of the parts, the maintenance staff can easily obtain the parts required for maintenance and perform maintenance work. The time until the start can be shortened, and the efficiency of maintenance work can be improved.
- the maintenance request manually input by the production staff includes information related to trouble that has occurred in the past (key for accessing history list: equipment number, etc.).
- the maintenance request includes information related to troubles that have occurred in the past, so maintenance personnel can efficiently carry out maintenance work while checking the information, and shorten the maintenance work time. It is possible to improve the efficiency of maintenance work.
- the maintenance request manually input by the production staff includes information on the maintenance staff's comments regarding the trouble that has occurred in the past (key for accessing the history list: equipment number, etc.).
- the maintenance request includes information related to comments from maintenance staff regarding troubles that have occurred in the past.Even for equipment that the maintenance person is in charge of for the first time, referring to the comments enables efficient maintenance work. This makes it possible to improve the efficiency of maintenance work.
- At least the call terminal 32 arranged on the production line 16 supports based on the instructions of the maintenance staff when the secondary judgment made after the start of the maintenance work by the maintenance staff is different from the primary judgment.
- the first support request processing unit 56A for making a request is included.
- the maintenance staff can efficiently advance the maintenance work together with the support staff, and the efficiency of the maintenance work can be improved.
- the support request is made by the maintenance person in the state where the equipment layout screen 94 showing the location of one or more production equipment installed at the production site is displayed on the call terminal 32 arranged on the production line 16. Implemented by input.
- the maintenance staff made a support request correctly for the equipment requiring the support request by making a support request while looking at the equipment layout screen 94. It can be easily confirmed.
- At least the call terminal 32 arranged on the production line 16 has a second support request processing unit that makes a support request when the elapsed time of maintenance work by the maintenance staff exceeds a preset time. 56B may be included.
- the time may be forgotten and the opportunity to request support may be missed. Therefore, when the elapsed time of maintenance work by the maintenance staff exceeds a preset time, a support request can be made, thereby reducing the burden on the maintenance staff.
- the maintenance staff can efficiently perform the maintenance work together with the support staff, and the efficiency of the maintenance work can be improved.
- At least the call terminal 32 arranged on the production line 16 outputs an alarm indicating an abnormality of the maintenance work when the elapsed time of the maintenance work by the maintenance person exceeds a preset time.
- the call terminal 32 arranged on the production line 16 has a maintenance plan display processing unit 50 that displays a maintenance plan of the production facility of the production line 16 based on instructions from the maintenance staff.
- the maintenance plan can be displayed using the call terminal 32 arranged on the production line 16 during inspection by a normal maintenance staff.
- the maintenance staff can quickly start maintenance work, and the frequency of maintenance requests can be reduced.
- the facility monitoring system 38 that monitors the operation status of the production facilities arranged in the production line 16 is provided.
- the facility monitoring system 38 detects an abnormality in the production facility, the maintenance staff office 12 A maintenance request is sent to the maintenance staff terminal 22 installed in the station.
- the maintenance staff terminal 22 further includes a request progress receiving unit 180 that receives the second maintenance request from the equipment monitoring system 38, and a maintenance management monitor 26 installed at least in the maintenance staff office 12 on the received second maintenance request. And an equipment layout display processing unit 52 for displaying the information.
- a maintenance request is sent to the maintenance staff terminal 22 installed in the maintenance staff office 12, so that the maintenance request is made more quickly than the maintenance request manually input by the production staff. Can be issued.
- the maintenance request by the equipment monitoring system 38 is displayed on the maintenance management monitor 26 installed in the maintenance staff office 12, the maintenance staff can recognize the maintenance request by the equipment monitoring system 38 at an early stage. Therefore, maintenance work for equipment requiring maintenance work can be carried out at an early stage.
- equipment maintenance support system and the equipment maintenance support method according to the present invention are not limited to the above-described embodiments, and various configurations can be adopted without departing from the gist of the present invention.
- a warehouse terminal 34 may be installed in each warehouse 18.
- the configuration of the warehouse terminal 34 may have the same configuration as the call terminal 32 and the maintenance staff terminal 22 described above.
- a person in charge of inventory management may use the warehouse terminal 34 to perform the warehousing process and the warehousing process.
- the barcode attached to the repair part may be read by the barcode reader 42 instead of manually inputting the information of the repair part. Thereby, inventory management of each warehouse 18 can be performed efficiently.
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Abstract
Description
本実施の形態に係る設備保全支援システム10は、図1に示すように、1以上の保全スタッフ事務所12、1以上の生産スタッフ事務所14、複数の生産ライン16及び複数の倉庫18を有する通常の生産工場に適用される。
先ず、コール端末32に備わる機能部は、図2に示すように、保全計画表示処理部50、設備レイアウト表示処理部52、第1保全要請処理部54A、第1応援要請処理部56A、第2応援要請処理部56B、交代要請処理部58、保全着手処理部60、保全中断処理部62、保全再開処理部64、保全完了処理部66、保全支援情報表示処理部68を有する。なお、設備監視システム38には、第2保全要請処理部54Bが組み込まれている。
設備メイン画面90は、例えば図4に示すように、各種ボタンが配列されたボタン表示領域100と、メッセージが表示されるメッセージ表示領域102等を有する。ボタン表示領域100には、例えば保全要請ボタン104、相談要請ボタン106、計画着手ボタン108、対応完了ボタン110等がある。
このプルダウンメニュー122は、例えば保全活動を支援するための複数の項目が配列された表示形態となっている。上から第1番目の項目(第1項目)を選択操作することで、応援・交代要請画面表示処理部70(図3参照)が起動される。応援・交代要請画面表示処理部70は、図7に示すように、応援・交代要請画面124を表示する。この応援・交代要請画面124には、応援要請ボタン126と交代要請ボタン128とがある。
例えば設備メイン画面90(図4参照)のメカ保全要請ボタン104a、電気保全要請ボタン104b、メカ相談要請ボタン106a、電気相談要請ボタン106b、応援・交代要請画面124(図7参照)のメカ応援要請ボタン126a、電気応援要請ボタン126b、メカ交代要請ボタン128a、電気交代要請ボタン128bのいずれかを操作することで、設備レイアウト表示処理部52(図2参照)が起動される。設備レイアウト表示処理部52は、図8に示すように、設備レイアウト画面94を表示する。
そして、生産スタッフ等が設備メイン画面90(図4参照)の例えばメカ保全要請ボタン104a、電気保全要請ボタン104b、メカ相談要請ボタン106a又は電気相談要請ボタン106bを操作して、設備レイアウト画面94(図8参照)を表示させた後、保全要請対象の生産設備を示すシンボル画像134を指でタッチあるいはペン状の器具でタッチ等することで、第1保全要請処理部54A(図2参照)が起動される。
第2保全要請処理部54Bは、図2に示すように、設備監視システム38に組み込まれている。第2保全要請処理部54Bは、生産ライン16に配置された設備の稼働状況を監視するセンサ36からの異常を知らせる信号の入力に基づいて起動され、当該設備で保全要請があったことを保全管理用サーバ20及び保全スタッフ端末22に知らせる。すなわち、保全要請情報を保全管理用サーバ20及び保全スタッフ端末22に送信する。この場合、例えばセンサ36の種類に応じてメカ又は電気の区分情報を含めるようにしてもよい。
生産スタッフ等が例えばプルダウンメニュー122(図6参照)の第1項目を選択操作することで、応援・交代要請画面表示処理部70(図2参照)が起動される。応援・交代要請画面表示処理部70は、コール端末32のディスプレイ32aに、応援・交代要請画面124(図7参照)を表示する。
保全担当者が出動した時点から所定時間(例えば90分、120分等)を経過した段階で、第2応援要請処理部56B(図2参照)が起動される。第2応援要請処理部56Bは、メカ関係又は電気関係の応援要請を行う。すなわち、第2応援要請処理部56Bは、第2応援要請情報を保全管理用サーバ20及び保全スタッフ端末22に送信する。第2応援要請情報は、例えば第2応援要請コード、送信元コード、メカ系統又は電気系統の種別及び設備コード等を含む。メカ系統又は電気系統の種別は、保全要請情報で使用された種別が使用される。第2応援要請処理部56Bは、応援要請と共に、保全作業の異常を示すアラームを出力する。
コール端末32のディスプレイ32aに応援・交代要請画面124(図7参照)が表示されている場合に、生産スタッフ等が例えばメカ交代要請ボタン128a又は電気交代要請ボタン128bを操作して、設備レイアウト画面94(図8参照)を表示させた後、交代要請対象の生産設備を示すシンボル画像134を指でタッチあるいはペン状の器具でタッチ等することで、交代要請処理部58(図2参照)が起動される。交代要請処理部58は、メカ関係又は電気関係の交代要請を行う。すなわち、交代要請情報を保全管理用サーバ20及び保全スタッフ端末22に送信する。
当該要請設備に到着した保全担当者が設備メイン画面90(図4参照)の保全着手/再開ボタン104cを操作することで、保全着手処理部60(図2参照)が起動される。保全着手処理部60は、保全担当者による保全着手があったことを保全管理用サーバ20に知らせる。すなわち、保全着手処理部60は、保全着手情報を作成して、保全管理用サーバ20に送信する。保全着手情報は、例えば保全着手コード、送信元コード、担当者コード、設備コード等を含む。
保全担当者が設備メイン画面90の保全中断ボタン104d(図4参照)を操作することで、保全中断処理部62(図2参照)が起動される。保全中断処理部62は、保全担当者による保全中断があったことを保全管理用サーバ20に知らせる。すなわち、保全中断処理部62は、保全中断情報を作成して、保全管理用サーバ20に送信する。保全中断情報は、例えば保全中断コード、送信元コード、担当者コード、設備コード等を含む。
保全中断中に、保全担当者が設備メイン画面90の保全着手/再開ボタン104c(図4参照)を操作することで、保全再開処理部64(図2参照)が起動される。保全再開処理部64は、保全担当者による保全再開があったことを保全管理用サーバ20に知らせる。すなわち、保全再開処理部64は、保全再開情報を作成して、保全管理用サーバ20に送信する。保全再開情報は、例えば保全再開コード、送信元コード、担当者コード、設備コード等を含む。
保全担当者が設備メイン画面90の対応完了ボタン110(図4参照)を操作することで、保全完了処理部66(図2参照)が起動される。保全完了処理部66は、保全担当者による保全対応の完了があったことを保全管理用サーバ20に知らせる。すなわち、保全完了処理部66は、保全完了情報を作成して、保全管理用サーバ20に送信する。保全完了情報は、例えば保全完了コード、送信元コード、担当者コード、設備コード等を含む。
図6のプルダウンメニュー122の第2項目を選択操作することで、設備稼働状況履歴表示処理部72(図3参照)が起動される。設備稼働状況履歴表示処理部72は、図12に示すように、ディスプレイ32aに設備稼働状況履歴画面144を表示する。この設備稼働状況履歴画面144は、主に、生産ライン名入力欄146aと、設備名入力欄146bと、検索ボタン146c等を有する。そして、保全担当者等が、生産ライン名入力欄146aに生産ライン名、設備名入力欄146bに設備名を入力し、検索ボタン146cを指でタッチあるいはペン状の器具でタッチ等することで、設備稼働状況履歴表示処理部72は、該当する設備の稼働状況の履歴を表示する。履歴の表示内容としては、発生したイベントの内容とイベントの発生時刻等が挙げられる。
図6のプルダウンメニュー122の第3項目を選択操作することで、保全作業状況表示処理部74(図3参照)が起動される。保全作業状況表示処理部74は、図13に示すように、ディスプレイ32aに保全設備作業状況一覧画面(全ラインモニター画面と記す)148を表示する。この全ラインモニター画面148には、主に、全製造ラインのうち、保全要請がなされた設備の現在の作業状況が一覧表示される。その内訳は、保全要請が行われた時刻(要請時刻)、稼働停止状態の経過時間(停止/経過時間)、製造ライン名、設備名、現在の作業状況、保全担当者名等が挙げられる。このうち、保全対応中の設備については例えば赤色で表示され、それ以外の設備については例えば青色で表示されて、保全対応中の設備を容易に見分けられるようになっている。
図6のプルダウンメニュー122の第4項目を選択操作することで、補修部品リスト表示処理部76(図3参照)が起動される。補修部品リスト表示処理部76は、図14に示すように、ディスプレイ32aに補修部品検索画面150を表示する。この補修部品検索画面150は、主に、リスト表示領域152aと図面表示領域152bとを有する。リスト表示領域152aは、補修部品の型式と部品名とがリスト形式で表示される。図面表示領域152bは、図示を省略するが、リスト表示領域152aへの選択入力(ポインタやタッチ等による選択入力)によって選択された補修部品の外観や透視図等が表示される。
図6のプルダウンメニュー122の第5項目を選択操作することで、在庫検索画面表示処理部78(図3参照)が起動される。在庫検索画面表示処理部78は、図15に示すように、ディスプレイ32aに在庫検索画面154を表示する。この在庫検索画面154には、主に、補修部品の型式入力欄156aと、部品名入力欄156bと、補修部品のリスト画面156cと、検索ボタン156dと、補修部品が保管されている複数の倉庫の位置を示す配置画面156e等が表示される。
保全完了後に、図6に示すプルダウンメニュー122の第6項目を選択操作することで、作業完了登録画面表示処理部80(図3参照)が起動される。作業完了登録画面表示処理部80は、先ず、ディスプレイ32aに設備別保全状況一覧140(図11B参照)を表示する。この設備別保全状況一覧140では、主に、保全要請がなされた日時(要請日時)と、設備名と、保全要請がなされたときの状況(要請時状況)と、現在の状況と、停止時間(分)等が表示される。
図6のプルダウンメニュー122の第7項目を選択操作することで、保全履歴リスト表示処理部82(図3参照)が起動される。保全履歴リスト表示処理部82は、図17に示すように、保全履歴リスト画面160を表示する。この保全履歴リスト画面160は、主に、項目入力領域162aと、履歴一覧表示領域162bとを有する。項目入力領域162aは、履歴一覧が膨大な情報量であるため、例えば期間、機種名、ライン名、設備名で絞って表示することができるようになっている。絞り込みのための項目としては、例えば期間、機種名、ライン名、設備名、作成状況、履歴種別等が挙げられる。
保全管理用サーバ20は、図19に示すように、要請進捗受付部180と、要請反映部182と、作業進捗反映部184と、保全履歴管理部186と、保全管理画面表示処理部188と、補修部品反映部190と、要請一時保存ファイル192と、作業進捗一時保存ファイル194とを有する。また、この保全管理用サーバ20には、保全履歴データベース198と補修部品データベース200とが接続されている。
次に、保全スタッフ端末22に備わる機能部について、図21を参照しながら説明する。
Claims (14)
- 生産現場に設置された1以上の生産設備の保全を支援する設備保全支援システム(10)であって、
少なくとも1以上のサーバ(20)と、1以上の端末(22、32)と、1以上の管理用モニタ(26、30)とが、保全スタッフ事務所(12)、生産スタッフ事務所(14)、倉庫(18)及び生産ライン(16)毎にそれぞれ必要に応じて配置され、
前記生産ライン(16)に配置された前記端末(32)からの保全要請を受け付ける手段(180)と、
複数の保全スタッフのうち、少なくとも前記保全要請の内容及び前記複数の保全スタッフの現況に基づいて、前記保全要請に応じた保全担当者の選任を行う手段(214)と、
選任された前記保全担当者の要請に従って、前記保全要請の内容に関連する少なくとも部品及び保全履歴に関する情報を保全支援情報として出力する手段(68)とを有することを特徴とする設備保全支援システム。 - 請求項1記載の設備保全支援システムにおいて、
前記生産現場に設置された1以上の生産設備の配置位置を示すレイアウト画面(94)を、少なくとも前記管理用モニタ(26、30)と前記端末(22、32)に表示する手段(52)と、
前記生産ライン(16)からの要請を前記レイアウト画面(94)に反映する手段(182)と、
前記保全担当者による保全作業の進捗状況を前記レイアウト画面(94)に反映する手段(184)と、を有することを特徴とする設備保全支援システム。 - 請求項1又は2記載の設備保全支援システムにおいて、
前記保全要請は、少なくとも機械的トラブルか電気的トラブルかを示す一次判断の情報を含むことを特徴とする設備保全支援システム。 - 請求項1~3のいずれか1項に記載の設備保全支援システムにおいて、
前記保全要請は、前記生産ライン(16)に配置された前記端末(32)に、前記生産現場に設置された1以上の生産設備の配置位置を示すレイアウト画面(94)を表示した状態で、生産スタッフの手入力によって実施されることを特徴とする設備保全支援システム。 - 請求項4記載の設備保全支援システムにおいて、
前記生産スタッフの手入力による前記保全要請は、少なくとも保全に必要な部品及び該部品の保管場所に関する情報を含むことを特徴とする設備保全支援システム。 - 請求項5記載の設備保全支援システムにおいて、
前記生産スタッフの手入力による前記保全要請は、過去に発生したトラブルに関する情報を含むことを特徴とする設備保全支援システム。 - 請求項6記載の設備保全支援システムにおいて、
前記生産スタッフの手入力による前記保全要請は、過去に発生した前記トラブルに対する保全スタッフのコメントに関する情報を含むことを特徴とする設備保全支援システム。 - 請求項3記載の設備保全支援システムにおいて、
少なくとも前記生産ライン(16)に配置された前記端末(32)は、前記保全担当者による保全作業の開始後になされた二次判断が前記一次判断と異なる場合に、前記保全担当者の指示に基づいて応援要請を行う手段(56A)を有することを特徴とする設備保全支援システム。 - 請求項8記載の設備保全支援システムにおいて、
前記応援要請は、前記生産ライン(16)に配置された前記端末(32)に、前記生産現場に設置された1以上の生産設備の配置位置を示すレイアウト画面(94)を表示した状態で、前記保全担当者の手入力によって実施されることを特徴とする設備保全支援システム。 - 請求項1又は2記載の設備保全支援システムにおいて、
少なくとも前記生産ライン(16)に配置された前記端末(32)は、前記保全担当者による保全作業の経過時間が予め設定された時間を超えた時点で、応援要請を行う手段(56B)を有することを特徴とする設備保全支援システム。 - 請求項10記載の設備保全支援システムにおいて、
少なくとも前記生産ライン(16)に配置された前記端末(32)は、前記保全担当者による保全作業の経過時間が予め設定された時間を超えた時点で、保全作業の異常を示すアラームを出力することを特徴とする設備保全支援システム。 - 請求項1記載の設備保全支援システムにおいて、
前記生産ライン(16)に配置された前記端末(32)は、前記保全スタッフの指示に基づいて、当該生産ライン(16)の生産設備の保全計画を表示する手段(50)を有することを特徴とする設備保全支援システム。 - 請求項1記載の設備保全支援システムにおいて、
前記生産ライン(16)に配置された生産設備の運用状況を監視する設備監視システム(38)を有し、
前記設備監視システム(38)は、前記生産設備の異常を検出した際に、前記保全スタッフ事務所(12)に設置された前記端末(22)に保全要請を行い、
前記保全スタッフ事務所(12)に設置された前記端末(22)は、さらに、前記設備監視システム(38)からの前記保全要請を受信する手段(180)と、受信した保全要請を少なくとも前記保全スタッフ事務所(12)に設置された前記管理用モニタ(26)に表示する手段(68)とを有することを特徴とする設備保全支援システム。 - 少なくとも1以上のサーバ(20)と、1以上の端末(22、32)と、1以上の管理用モニタ(26、30)とが、保全スタッフ事務所(12)、生産スタッフ事務所(14)、倉庫(18)及び生産ライン(16)毎にそれぞれ必要に応じて配置され、生産現場に設置された1以上の生産設備の保全を支援する設備保全支援システム(10)にて使用される設備保全支援方法であって、
前記生産ライン(16)に配置された前記端末(32)からの保全要請を受信するステップと、
複数の保全スタッフのうち、少なくとも前記保全要請の内容及び前記複数の保全スタッフの現況に基づいて、前記保全要請に応じた保全担当者の選任を行うステップと、
選任された前記保全担当者の要請に従って、前記保全要請の内容に関連する少なくとも部品及び保全履歴に関する情報を保全支援情報として出力するステップとを有することを特徴とする設備保全支援方法。
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